Thermostatic control



Feb. 10, 1942. M. w. EATON THERMOSTATIC CONTROL Filed F'eb. 2, 1939 3 Sheets-Sheet l MAL c0014 WEA 70N Feb. l0, 1942. Mjw. EATON THERMosTATIc CONTROL Filed Feb. 2, 1939 3 Sheets-Sheet 3 L m w B Patented Feb.1o,1942 t 2,272,458

UNITED STATES PATENT 'OFFICE THERMOSTATIC CONTROL Malcolm W. Emu, Freeport, nl., assigner to Micro Switch Corporation, Freeport, Ill., a corporation ot Illinois Application February 2,- 1939, Serial No. 254,140

12 Claims. (Cl. 200-138) n The present invention relates generally to For convenience in the description, the view of thermostats, and more particularly to snap actthe thermostatic controller as shown in Fig. 3 is ing bimetal electric thermostats. referred to as a plan of view, Fig. as a side ele- Objects of the invention include the provision vational view, and Figs. 4 and 6 as end elevaof an improved snap acting thermostatic switch 5 tions, and the other figures are referred to simand thermal relay, and the provision of an imilarly. i proved circuit controlling protector for electric In Figs. 1 and 2, a thermal protective device motors and the like. These and other objects will designated generally by the reference numeral I0 become apparent as the following description is shown mounted within the end bell of an elecproceeds. The invention resides in certain new tric motor where it is exposed to the internal heat and improved features of construction, combinaof the motor. The Ventilating air for the motor tions of elementsand arrangements of parts, and enters the end bell at the left of the'motor houscertain specific embodiments thereof, shown and ing through the opening 8, circulates` through the described herein, serve by way of example to motor, and leaves the housing from the end bell illustrate the manner iny which the invention at the right of the machine as seen in Fig. 1,

may be usedv and practiced. lthrough the exit opening 9. The thermal pro- Certain constructions and arrangements of aptector I0, being located in the right end bell as paratus, herein shown and described, are deshown in Fig. 1, is exposed to the Ventilating air scribed Vand claimed in the co-pending applicaafter it has been warmed by its passage across tion of M. W. Eaton, Serial No. 174,042, filed Nothe motor windings, etc. In addition the thermal vember 11, 1937, now Patent 2.1721373, issued protector I0 is exposed to radiation from the September 12, ,1939. I various internal parts of the motor. This ther- In the drawings, l fe p mal protector Il) controls the power circuit of the Figs. land 2 are side and end views respectivemotor and operates to deenergize the motor in ly, of an electric motor, having the thermostati'c 25 response to the occurrence of high temperature control device of the present invention mounted or overload vconditions in a manner to be dein the end-bell thereof;

scribed presently. l

Fig. 3 illustrates a thermostatic protector for yThe thermal protector I0 itself is illustrated in l an electric motor constructed according to my Figs. 3 to 7 and includes a molded insulating present invention and includes a diagrammatic base II', a generally U-shaped snap acting, birepresentation of v an electric motor protected metallic thermal element I 2,carrying a moving thereby; l contact I4, and a pair of stationary electric con- Figs-4, 5, 6, and'7 are additional views ofthe 4^. tacts I6 and I8.` The molded insulating base II thermostatic controlling device of Fig. 3; includes an elongated, plate-like bottom portion Fig. 8 illustrates, a modification of the con- 35 20, a partially bifurcat'ed insulating post 22 at ystruction of Fig..5; one end for supporting the bimetallic element I2 Fig. 9 illustrates the thermostatic protector of and its terminals, a pair ofposts 24 at its other Flg'.' 3 in a different circuit arrangement for proend for supporting the two stationarycontacts tecting an electric motor;E l l I6 and I8 and a pair of threaded metal inserts Figs. l0 andll illustratealternate circuit ar- 40, 26 in the plate-like portion 20 for mounting the rangements for the lsystem of` Fig. 9; device in an electric motor or the like. Each of Fig. 12 illustrates a modification of thetherthe two stationary contactA plates I 6 and I8 is mostatic controller of Fig. 3,V and" includes a diagenerally L-shaped, as shown in Fig. 7, to programmatic representation of still `another circuit vide a contact area for engaging `the movable f or protecting control system; 45 contact I4, a mounting tab for supporting it, Fig. v13 illustrates another modied. thermoand a notch for .clearing the mounting screw of static circuit controller, alnd a diagrammatic rep- ,the other contact. o A formed terminal tab, ex` resentation of an electric motorprotected` theretending from the mounting tab lengages the side by; f l h of the insulating supporting post to hold the con- Figs.l` 14 and 15 are additional views of the 50vtact plate in proper alignment. These contact thermostat of Fig. 13 plates lextend from their mountings toward the Figs. 16"and 17 illustrate a modification of thel center of the device, as best .seen in Fig. 5, to thermostatic protector of Figs. 13 and 14; and,A provide two opposed contact surfaces or.stops,

Fig` 18 illustrates a furthermo'diflcation thereone above the other, for engaging the moving of. i l .65 contact Il.

The bimetallic snap/acting element I2 is made from a single strip of bimetal, slotted the greater portion of itsi length so'that the element I2 is generally U-shaped with two substantially parallel legs 32 and 34 carrying the movable contact I4 at their Joined end. At the open end of the U, each leg is mounted on a separate projection of the insulatingpost 22 so as to be insulated thereby from the other leg. Formed metal terminal members 36 and 38 are clamped by the same screws 40 and 42 that hold thevbimetal legs 32 and 34 on the portion 22 of the insulating base. The U-shaped` bimetal piece formed that in its normally Ilat unstressed condition the distance between the two mounting holes in the legs 32 and 34 is slightly greater than the spacing between the threaded holes for receiving the mounting screws 40 and 42. Consequently, when mounted under the screws 40 and 42, the two legs 32 and 34 of the bimetal element are drawn slightly together.

This drawing together of the two legs of the U serves to stress the bimetal element I2 as a whole and to force the individual legs to twist slightly to deflect the unmounted contact carry- .ing end of the bimetal into engagement with one of the stationary contacts I6 and I8. The device illustrated in Figs. 3 to 7 inclusive is so constructed that the high expansion material of the bimetal is on the lower face of the element I2, and the whole device is constructed and arranged so that at ordinary atmospheric temperatures the legs 32 and 34 of the bimetal element I2 take l,a twisted position wherein the inner edges of' the legs 32 and 34 (next the central longitudinal slot) lie above the outer edges. This elevation oi' the central edge is greatest midway between the two ends of the bimetal element I2. In this. its normal position, the bimetal spring I2 holds the moving contact I4 in iirm engagement with the lower stationary contact I E. Then at some higher temperature the legs 32 and 34 twist in the opposite direction so that the bimetal spring I2 holds the moving contact I4 in firm engagement with the upper stationary contact I8.

Accordingly, at ordinary atmospheric temperature the bimetal element I2 holds the movable contact I 4 in firm engagement with the lower stationary contact I6 to provide a substantial contact pressure between the contact surfaces. As the temperature of the bimetal element 'is gradually raised, the bimetal element at first executes substantially no motion of the contact and so permits the contacts I4 I2 is so yto the temperature of the air within the motor housing, and connected in circuit with the starting and running windings of the motor as shown in Fig. 3, it responds to the value of current drawn by the motor, and thereby responds in a measure to the rate at which heat is generated within the motor.

In the circuit diagram of Fig. 3, a power conductor 50 is connected directly to the starting winding 52 and the running winding 54 of a split phase induction motor 56. The other power conductor 5I is connected to the lower stationary contact I6 of the thermal protective device I0 so that, when the thermal element I2 is in its normal cool position, with the moving contact I4 in engagement with the stationary contact I6, thecircuit is completed through the separate legs 32 and 34 of the bimetal element I2 to the running and starting windings respectivelyf of the motor 5S. Included in series with the starting winding 52 is the usual centrifugal starting switch 58 for disconnecting the starting winding 52, after the motor has come up to speed. A lamp 6D is connected across the two stationary contacts l5 and I3 to indicate the operated condition of the thermal protector.

In operation, the bimetal element l2 normally holds the movable contact I4 in engagement with the stationary Contact IB to complete the circuit to the windings of the motor; but when heated, either by the air within the motor houring or by 'the current passing through the bimetal element itself to the motor windings, it snaps up against the stationary contact I3 to open the motor circuit at the contacts I4 and I6 and to connect the pilot light 60 in series and I6 to remain in firm engagement with each i other, all until a certain temperature is reached, at which temperature the bimetal element I2 suddenly snaps `to twist the bimetal legs in the opposite direction, and in so doing carries the greater expansion of the lower. face of the bimetal element or spring tends more and more to produce this reversal of the twist, but that tendency is opposed by the initial strain of the with the motor windings. The pilot light BU has a much higher resistance than that of the motor windings so that the lamp current flowing in the circuit to energize the lamp is negligible insofar as the motor is concerned. The light 6I) provides la visual indication that the thermostatic protector has operated to deenergize the motor windings. With the motor deenergized, both the motor itself and the bimetal element I2 gradually cool until the bimetal element again snaps back to its normal position to again energize the motor to cause it to resume` operation. 1f abnormal conditions persist, the bimetal element I2 will, after a time, againheat up and disconnect the motor from the line for a length of time sufficient to permit the motor tococl again to a temperature low enough to prevent overheating on a subsequent 'energization During" the normal running condition of the metan/*the starting winding is open at the centrifugal starting switch 58 so that current is carried only by the wider leg 32 of the bimetal bimetal element as already described' until the stored stresses in the material become vsuiliciently great to overcome that initial. strain of its normalvshape or position and so carries the 74 element I2, and the heating eiect of the motor current on the thermostatic protector is determined by the electrical resistance of this leg It will be clear, fhowever, that ralthough under running conditions, vthe heat is generated only in the bimetal leg 32, `that heat is generated comparatively slowly and is conducted from the leg 32to the leg 34 so that both legs oi the bimetal element will be at about the same temperature. Furthermore, both of the legs 32and 34 will respond to the temperature of the air y' within the motor housing.

During the starting condition of the motor, current for the starting winding is drawn -through the narrow bimetal leg 34 to energize the the line quickly, often within just a few seconds. During the starting condition, the running winding 54 itself draws a current several times its normal full load running current so as to gen; erate heat rapidly in the bimetal element 32, but this rate of heat generation still may not be high enough to give the motor as `great a degree of protection under stalled conditions as it enjoys against overload during the running condition, partly because the starting winding has a high resistance and so generates heat within the motor rapidly. Therefore, the bimetal leg 34 is made narrow to present a high resistance to the current of the startingy winding so as to match the high rate of heating of that winding of motor with a high rate of heating of the thermal protector and thereby to match the heating effects in the two bimetal legs 32 and 34 to the protective requirements of the two separate windings. Preferably, the resistance of the narrow leg 34 is made great enough with respect to the resistance of the wider leg 32, and with respect to the relative values of current drawn by the starting and running windings under Y stalled conditions, that the current of the starting winding 52 is made to generate more heat in the narrow leg of the bimetal element than it would add to the other leg if it were drawn with the running current through the wider lg 32.

more quickly than it would if the" total current for both windings were drawn through the single leg 32.

Fig. 8 illustrates a modification of the thermal protective element of Fig. 3, wherein means are provided for adjusting the thermal element to alter its operation. In Fig. 8, insulating post 23 for supporting the bimetal element I2 is slightly shorter than the corresponding insulating post 22 of the device of Fig. 2, and a plate 3| of insulating material is mounted atop the post 23 under the mounted ends 0f the two 'legs of the bimetal element I2. This insulating plate 3| extends out over the central plate portion 20 of the insulating base, under the bimetal element I2 and is engaged by an adjusting screw 33 threaded into the insulating base 20. This screw 33 turns up against the unmounted end of the plate 3| to flex it upwards, and the plate 3| in turn bears against the under face 'of the bimetal element I2 to oppose the tendency of the element to operate and so to require it to attain av higher temperature before it snaps to actuate the moving contact I4. Terminal members such as 36 and 38 of Fig. 3 are omitted under the legs of the bimetal element I2y so as to permit the bimetal element to lie against the adjusting plate 3|.

Figs. 9, 10, and 11 illustrate a motor protector similar to that of Fig. 3 in a different type of motor protecting circuit, wherein the thermostatic protector of my present invention has the advantage of being easily adapted to the protection of motors of different sizes. In Fig. 9, the motor 66 is controlled by only a single circuit. This motor may be of the repulsion induction type, or may be a split phase motor or other type wherein the connections to the starting winding are not brought out from the motor to the protector separately from the connections of the running winding. In Fig. 9 the line connection is made to the protector at the stationary contact I6 (as in Fig. 3), and themotor connection is made to the mounted end of the wide leg 32 of the bimetal element I2. In this system, the entire motor current is carried by this lleg 32 during both the starting and running conditions of the motor. The dimensions of the bimetal leg 32 and the electrical resistivity thereof must be of the correct values to match the heating effect of the current on the bimetal elements to the heating eiect of the current on the motor 66 itself. Accordingly, a par--l ticular thermostatic protector of given dimensions and adjustments will best protect a motor of a particular size, when connected in circuit Vwith that motor in the manner shown in Fig. 9.

vlower value of current than is required by Fig. 9.

The thermostatic protector illustrated in Fig. I2 is similar to that illustrated in Fig. 3 with the exception that the two legs 33 and 35 of its bimetal element I3 are of the same width so as to be substantially equal in electrical resistance. In the system of Fig. 12, the motor 66 is controlled by a manually closeable circuit breaker or electric contactor 68 having a-holding coil l0 which when energized maintains the circuit to the motor 66 closed. The mounted ends of the bimetal legs 33 and 35 are connected in series with the circuit through the motor 66, so that the entire motor current passes along one leg of the U tothe joined or contact end and back along the other leg and so traverses the full length of each separate bimetal leg. This bimetal element I3 being connected in one side of the motor circuit, is at substantially the potential of one of the line conductors. The holding coil 'III of the circuit breaker is connected between the stationary contact I6 and the other line conductor so that when the thermal protector is .in its normal or cold position (the circuit breaker 68 having been closed manually to energize the motor), the holding coil 'I0 remains energized to hold the circuit breaker 63 in its closed position. When the bimetal element I3 Yresponds to excessive temperature or excessive current of the motor 66 to snap away from the stationary contact I6, it opens the circuit through the holding magnet I0 and so permits the contactor 63 to open to deenergize the motor 66. Upon cooling, the thermal element I3 recloses the connection to the contact I6, but this I cooling of the thermal element I3 does not automatically restart the motor but merely restores mits the'motor to be again put into operation, manually.

Figs. 13, 14, and illustrate still another modification of the thermostat of Fig. 3. Referring to Fig. 13, a U-shaped bimetal element 'i6 has a pair oi legs 18 and 80, which are joined together at the mounted end 82 of the thermal element. The open end of the U-shaped piece of bimetal is closed by a metal bridge 8l pinned or riveted to the separate bimetal legs 18 and 80, and of such size that'l the bimetal legs 'I8 and 8U, when riveted thereto are drawn slightly together to give the bimetal spring as a whole, a strain similar to that of the bimetal element I2 of the thermostat of Fig. 3. The bridge 84 constitutesa movable contact member and moves between stationary contacts I6 and IB. This thermostat of Fig. 13 is otherwise substantially like the thermostat oi Fig. 3. In Fig. 13, the thermostat is shown connected in series with an electric motor il, although' it will be understood that the thermostat is in fact mounted inside of the motor 66, which is here represented onlydagrammatically.

The thermostats of Figs. 3 and 12 possess the advantage over that of Fig. 13 of providing two separate bimetal paths for electric current so that the device is' adaptable to a wider variety of circuit arrangements. The device of Fig. 13 has the advantage that the strain imposed upon the bimetal legs oi' the thermal element is not carried by the insulating mounting base sol that the support for the thermal element need not be as rugged, and further need not be made to such exacting dimensions.V

Figs. 16 and 17 illustrate a modification of the thermal protector of Figs. 13, 14 and 15, wherein means are provided for manually actuating the snap acting element of the protector to open and close the motor energizing circuit. As shown in Fig. 16, in this modification the thermal bimetal element 82 is constructed with its high expansion material at its upper face so that the thermal element normally holds its moving contact 94 in engagement with the upper stationary contact 96, and when heated snaps the moving contact down away from this upper stationary contact. This modication omits the lower stationary contact which, in the device of Fig. 14, serves as a stop for the snap acting bimetal element. Instead, the device of Fig. 16 includes a manually operable button 88 mounted in the insulating base 2|. This manual button serves as the lower stop for the bimetal snap acting element 82, and is so dimensioned'that when held in its uppermost position, it provides a stop spaced below the stationary contact just sumciently far that the bi metal element 82, when cooled, can snap back to its normal position (the position shown in Fig. 1d) and so that when vthe button 98 lies away from its uppermost position it permits the free end (the left end as seen in Fig. 16) of the birnetal element 82 to move down so far that the bimetal element, even after cooling to ordinary atmospheric temperatures will not snap back unaided to its normal position. Accordingly, th'e protector of Fig. 16 operates in response to a high temperature to open the circuit through its contacts just as does the thermal protector of Fig. 14, but can snap back to its circuit closing position only when both it itself has cooled to the same extent as is required of the thermostat oi' Fig. 14, and also the manual push button 98 is held in its uppermost position. Accordingly, theresetting or circuit closing operation of the device oi Fig. 16 is non-automatic in th'at the device does not reclose an interrupted circuit without manual actuation of button 98, and it is "trip-free in that lt cannot be reclosed manually as long as its thermal element remains at a high temperature.

The device of Fig. 16 includes also a second manual push button |02 adapted to be forced upward against the lower face of the brnetal element 92 near its mounted end and just to one side of its central longitudinal slit. The pin iD! engages the bimetal element at the point lill indicated in Fig. 17. An upward pressure exerted by the push button 102 at this point induces a normal snap action of the resilient bimetal element even though the bimetal element be at a low temperature, and so causes the moving contact to snap down away from the stationary contact against the pin 98 and so open the'circuit. When so opened the `device may be reclosed im mediately by moving the pin 98 to its uppermost position. Accordingly, the manual push buttons 98 and ID2 constitute manual on and ofi" buttons for a, manual control of the operation oi the motor or other device connected thereto, as long as that operation does not produce an excessive temperature of the bimetal element 82. Should the bimetal element reach a high' temperature, that high temperature prevents the reclosing oi the circuit.

Fig. 18 illustrates a modiilcation of Fig. 16 wherein the device in Fig. 16 is provided with an adjustment similar to that of Fig. 8. A formed metal plate IDB is clamped under the same screws that support the bimetal element S2 and a screw I 08 threaded into an insert in the base permits the plate l 06 to be bent down against the bimetal spring 92 to adjust the temperature at which it snaps.

While the thermal motor protectors as illus trated and described herein respond both to the motortemperature, and to the motor current. they can be made to respond to only one or the other. Thus, if the bimetal element is made with a low resistance so that the heating effect of the motor current is negligible, the device acts essentially as a thermostat only, and so responds only to motor temperature. But if instead, the bimetal element', is located outside of the motor housing so as to be unaifected by motor heat, it acts only as a thermal relay and responds only to motor current. the specific constructions herein shown and described by Way of example and illustration, but embraces all modifications and variations as iall within the scope of the appended claims.

I claim:

1. In combination in an apparatus of the character described, a U-shaped thin leaf spring of composite bimetal, the legs of the U being substantially parallel to each other, and the legs being held in a strained relationship at the open end of the U to cause the spring as a whole normally to assume a strained position, whereby said spring snaps automatically from one stable position to another in response' to changes in temperature.

2. In combination in a device of the class described, a U-shaped, elongated thin leaf spring of composite bimetai mounted at one end, the legs of said U being substantially parallel to each other and held pulled together at the open end of the bimetal U to cause the spring as a whole normally to assume a strained position, whereby said bimetal spring snaps automatically from one stable position to another in response to a change of temperature to move the unmounted* The invention is not limited to end of the spring from one position to another with a snap action, a movable stop for the free end of said bimetal spring to limit its motion in one direction in which it snaps in response to a change'of temperature and thereby to determine one of said stable positions of said spring, said movable stop being manually movable to vary said one stable position of said spring, whereby to vary the temperature which said spring m'ust attain before snapping automatically out of said one stable position.

3. In combination in a device of the class described, a, U-shaped thin leaf spring of composite bimetal mounted at one end of its U, the legs of the U being held in a strained relationship at the open end of the U to cause the spring asl a whole normally to assume a strained position, .whereby said spring snaps through an mal low temperature, it may be actuated without a change of temperature to snap back and forth between said two stable positions in response to actuation by said means for applying pressure and by said movable stop, and whereby said bimetal spring may be made to snap into its normal low temperature position only when said bimetal spring itself has cooled to a predetermined temperature and said movable stop is moved in the'direction toward said bimetal spring.

6. The combination of claim 1v wherein mounting means support the bimetal spring at the open end `of the U, and wherein said spring is held in said strained relationship solely by its mounting. t

7. The combination of claim 1 wherein insulating mounting material supports lsaid U- shaped bimetal spring at the open end of said U,. and wherein said legs are held in strained relationship solely by said insulating mounting material, and contact means carried by the mov- Y able free end of said bimetal spring, whereby positions to the other without a change of temv perature, `and in so doing, causing the unmounted end of said spring to move through a distance greater than the movement required of said means in initiating said snap action.

4. The combination of claim 3 wherein said U-shaped bimetal springv is mounted at the closed end of the U andwherein the strained relationship of the legs of the U consist in the ends of the legs'at the open end of the bimetal' 4held pulled together at the open end o f the bimetal U to cause the spring as a whole normally .to assume a strained position, whereby said bimetal spring snaps from one stable strained position to another in response to a change of temperature to move the unmounted end of the spring from one position to another with a snap action, means for applying pressure to the bi- ,metal spring near the mounted end thereof for causing said spring to snap from one stable position to another in the direction in which the change would have occurred in response to the rise of temperature, but to do so without a change 'of temperature, a stop for the f ree end of said bimetal spring to limit its 'motion in the direction in which it snaps in response to a lowering of temperature, a movable stop for limiting the snap movement of the free end of said spring when it snaps in response to an increase in temperature, said movable stop being manua y movable to vary the high temperature position of said spring whereby to vary the temperature to which said spring must be cooled for effecting a snap action upon a lowering of temperature, and an abutment for said manually movable stop for so limiting the motion thereof toward .said bimetal spring (in the direction in .which said bimetal spring snaps in response to a loweringof temperature), as to prevent said movable stop fromv holding said bimetal spring against the first mentioned stop,

y whereby, when said bimetal spring is at a noreach separate leg of said U provides a separate electrically conducting path from said contact.

8. The combinati-on' of claim 1 wherein the separate legs of said U are of different widths, but wherein each separate leg of said U is of substantially uniform width throughout the greater portion of its length, whereby said legs have different electrical and mechanical properties.

9. The combination of claim l wherein said bimetal` spring is mounted in cantilever fashion at one end thereof, and wherein there is provided an adjustable means for applying pressure to one face of said spring near the mounted end thereof for altering the temperature at which said spring snaps from one stable strained position to the other.

10. In combination in an apparatus of the character described, an elongated spring having a longitudinal slot dividing the spring into two approximately parallel elongated legs, said slot terminating short of the two ends of the.

spring so as to leave end portions thereof connecting the two legs, said legs being constructed of thin composite bimetal, the connecting portion at one end of said legs being so formed that it tends to swing the legs to bring the opposite ends thereof to a different distance apart than that at which they are held by the connecting portion at said opposite end, whereby said opposite connecting portion inholding said legs as aforesaid, imposes a bending stress upon the first connecting portion and causes said spring to assume a strainedvconguration, and whereby further said spring snaps automatically through an unstable conformation, from one stable conformation to another in response to changes in temperature.

l1. The combination of claim` lwherein insulating mounting means supports the legs of said bimetal U at the open end thereof and insulates said legs from each other, -whereby each separate leg'ofv said U may constitute a part of a separate electrically conducting path from the closed end of said bimetal U.

12. The combination of claim 1, wherein in- .sulating mounting' means supports the legs of said U at the openV end thereof and insulates said legs from each other.. at said mounted end,

and wherein said separated legs of the U have different electrical resistances.

MALCOLM W. EATON. 

